1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2011 SAE International All rights reserved. No part of this p
3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497
4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AMS4177D AEROSPACE MATERIAL SPECIFICATION AMS 4177 REV. D Issued 1976-01 Revised
5、2006-09 Reaffirmed 2011-11 Superseding AMS 4177C Core, Flexible Honeycomb, Aluminum Alloy For Sandwich Construction 5056, 350 (177) RATIONALE This document has been reaffirmed to comply with the SAE five-year review policy. 1. SCOPE 1.1 Form This specification covers an aluminum alloy in the form of
6、 honeycomb core in a non-hexagonal, flexible cell configuration, the core being treated for increased corrosion resistance and furnished only in the expanded form. 1.2 Application This honeycomb core has been used typically in contoured sandwich construction for short-term service up to 350 F (177 C
7、) or for long-term service up to 200 F (93 C), but usage is not limited to such applications. 1.3 Safety - Hazardous Materials While the materials, methods, applications, and processes described or referenced in this specification may involve the use of hazardous materials, this specification does n
8、ot address the hazards which may be involved in such use. It is the sole responsibility of the user to ensure familiarity with the safe and proper use of any hazardous materials and to take necessary precautionary measures to ensure the health and safety of all personnel involved. 2. APPLICABLE DOCU
9、MENTS The issue of the following documents in effect on the date of the purchase order forms a part of this specification to the extent specified herein. The supplier may work to a subsequent revision of a document unless a specific document issue is specified. When the referenced document has been
10、cancelled and no superseding document has been specified, the last published issue of that document shall apply. 2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.
11、org. AMS 4005 Aluminum Alloy Foil, 5.0Mg - 0.12Mn - 0.12Cr (5056-H191), Strain Hardened SAE AMS 4177D Page 2 of 11 2.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM B 117 Operating Sa
12、lt Spray (Fog) Apparatus ASTM C 273 Shear Properties in Flatwise Plane of Flat Sandwich Constructions or Sandwich Cores ASTM C 365 Flatwise Compressive Strength of Sandwich Cores 2.3 U.S. Government Publications Available from the Document Automation and Production Service (DAPS), Building 4/D, 700
13、Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, http:/assist.daps.dla.mil/quicksearch/. FED-STD-595 Color 3. TECHNICAL REQUIREMENTS 3.1 Material 3.1.1 Metal Shall be AMS 4005 aluminum alloy foil. 3.1.2 Adhesive The adhesive used to bond the foil shall be of such quality that the resu
14、ltant core shall meet the requirements of 3.4 and 3.5. 3.2 Configuration The core material shall consist of strips of aluminum alloy foil bonded together to form cells of approximately uniform shape as shown in Figure 1. 3.2.1 Designation Core shall be designated according to the following numbering
15、 system: Nominal density, pounds per cubic foot (kg/m3) (See 4.5.1) Cell count, per linear foot (m) of transverse direction (See 4.5.2) Foil thickness in ten-thousandths inch (m) “N” for nonperforated or “P” for perforated (See 3.2.2) “F” for flexible “T“ for treated Alloy Adhesive, option of suppli
16、er Example in inch/pound units: Core with a nominal density of 2.1 pounds per cubic foot with a cell count of 40, 0.0014 inch foil thickness, nonperforated, flexible, treated, made of 5056 aluminum alloy, and bonded with required adhesive shall be numbered as follows: 2.1-40-14 NFT5056 (XXXX) Exampl
17、e in SI units: Core with a nominal density of 34 kg/m3with a cell count of 131, 36 m foil thickness, nonperforated, flexible, treated, made of 5056 aluminum alloy, and bonded with required adhesive shall be numbered as follows: 34-131-36 NFT5056 (XXXX) SAE AMS 4177D Page 3 of 11 3.2.2 Perforation Fo
18、il shall be nonperforated, except that, when perforation is specified, the perforations shall be of such size and location that all cells are vented at least once for each 0.250 inch (6.35 mm) of core thickness. 3.3 Conditions The core shall be treated for corrosion resistance. 3.4 Properties Core s
19、hall conform to the following requirements; tests shall be performed, on the core supplied, in accordance with specified test methods: 3.4.1 Stabilized Flatwise Compressive Strength Shall be as specified in Table 1 and Table 2, determined in accordance with ASTM C 365 on six specimens 0.625 inches (
20、15.88 mm) in thickness. TABLE 1A - MINIMUM COMPRESSIVE STRENGTH AT 77 F, INCH/POUND UNITS Core Designation Individual Compressive Strength psi 2.1-40-14 NFT5056 3.1-40-20 NFT5056 4.1-40-26 NFT5056 4.3-80-14 NFT5056 6.5-80-20 NFT5056 8.0-80-26 NFT5056 182 329 483 518 910 1260 TABLE 1B - MINIMUM COMPR
21、ESSIVE STRENGTH AT 25 C, SI UNITS Core Designation Individual Compressive Strength MPa 34-131-36 NFT5056 50-131-51 NFT5056 66-131-66 NFT5056 69-262-36 NFT5056 104-262-51 NFT5056 128-262-66 NFT5056 1.26 2.27 3.33 3.57 6.27 8.69 SAE AMS 4177D Page 4 of 11 TABLE 2A - MINIMUM COMPRESSIVE STRENGTH AT 347
22、 F, INCH/POUND UNITS Core Designation Individual Compressive Strength psi 2.1-40-14 NFT5056 3.1-40-20 NFT5056 4.1-40-26 NFT5056 4.3-80-14 NFT5056 6.5-80-20 NFT5056 8.0-80-26 NFT5056 119 215 315 340 595 820 TABLE 2B - MINIMUM COMPRESSIVE STRENGTH AT 175 C, SI UNITS Core Designation Individual Compres
23、sive Strength MPa 34-131-36 NFT5056 50-131-51 NFT5056 66-131-66 NFT5056 69-262-36 NFT5056 104-262-51 NFT5056 128-262-66 NFT5056 0.82 1.48 2.17 2.34 4.10 5.65 3.4.2 Shear Strength Shall be as specified in Table 3 and Table 4, determined in accordance with ASTM C 273 using five specimens 0.625 inch (1
24、5.88 mm) in thickness: TABLE 3A - MINIMUM INDIVIDUAL SHEAR STRENGTH AT 77 F, INCH/POUND UNITS Core Designation Ribbon Direction psi Transverse Direction psi 2.1-40-14 NFT5056 3.1-40-20 NFT5056 4.1-40-26 NFT5056 4.3-80-14 NFT5056 6.5-80-20 NFT5056 8.0-80-26 NFT5056 74 151 217 235 364 506 42 90 132 13
25、8 213 307 TABLE 3B - MINIMUM INDIVIDUAL SHEAR STRENGTH AT 25 C, SI UNITS Core Designation Individual Ribbon Direction MPa Individual Transverse Direction MPa 34-131-36 NFT5056 50-131-51 NFT5056 66-131-66 NFT5056 69-262-36 NFT5056 104-262-51 NFT5056 128-262-66 NFT5056 0.51 1.04 1.50 1.62 2.51 3.49 0.
26、29 0.62 0.91 0.95 1.47 2.12 SAE AMS 4177D Page 5 of 11 TABLE 4A - MINIMUM INDIVIDUAL SHEAR STRENGTH AT 347 F, INCH/POUND UNITS Core Designation Ribbon Direction psi Transverse Direction psi 2.1-40-14 NFT5056 3.1-40-20 NFT5056 4.1-40-26 NFT5056 4.3-80-14 NFT5056 6.5-80-20 NFT5056 8.0-80-26 NFT5056 48
27、 97 141 156 236 330 30 59 86 91 139 200 TABLE 4B - MINIMUM INDIVIDUAL SHEAR STRENGTH AT 175 C, SI UNITS Core Designation Ribbon Direction MPa Transverse Direction MPa 34-131-36 NFT5056 50-131-51 NFT5056 66-131-66 NFT5056 69-262-36 NFT5056 104-262-51 NFT5056 128-262-66 NFT5056 0.33 0.67 0.97 1.08 1.6
28、3 2.28 0.21 0.41 0.59 0.63 0.96 1.38 3.4.3 Node Bond Strength Shall be as shown in Table 5, determined in accordance with 4.5.3. TABLE 5 - MINIMUM INDIVIDUAL NODE BOND STRENGTH Property Cells per 40 Linear Feet Cells per 80 Linear Feet Cells per 131 Linear Meters Cells per 262 Linear Meters Node Bon
29、d Strength at room temperature 30 pounds force 35 pounds force 133N 156N 3.4.4 Flexibility A core slice shall lie flat without crimping, permanent distortion, or delamination when flexed as specified in 4.5.4. 3.4.5 Corrosion Resistance The core shall show a weight loss not greater than 125 milligra
30、ms per square foot (1345 mg/m2) of exposed foil area, determined in accordance with 4.5.5. 3.5 Quality Core, as received by purchaser, shall be free from imperfections detrimental to usage of the core. Core shall be clean and free from grease, oil, trim scraps, and impurities. The foil edges of the
31、core shall be free from notches, crush lines, and rolled metal. The core shall have no more than three node bond breaks per square foot (32/m2) with no more than two connected node breaks per square foot (21/m2). The core shall have no more than four unexpanded cells per square foot of core (43/m2).
32、 The core shall not have more than 10 multiple laps for each 36 x 96 inch (914 x 2438 mm) sheet of core. 3.6 Sizes and Tolerances 3.6.1 Sizes Length (L), width (W), and thickness (T) of each panel shall be as ordered. SAE AMS 4177D Page 6 of 11 3.6.2 Tolerances Shall be as shown in Table 6. 3.6.2.1
33、Thickness TABLE 6A - THICKNESS TOLERANCES, INCH/POUND UNITS Nominal Thickness Inches Tolerance, Inch plus and minus 0.250 to 4.000, incl Over 4.000 to 10.500, incl 0.005 0.062 TABLE 6B - THICKNESS TOLERANCES, SI UNITS Nominal Thickness Millimeters Tolerance, Millimeters plus and minus 6.35 to 101.60
34、, incl Over 101.60 to 266.70, incl 0.13 1.57 3.6.2.2 Cell Count The “W” cell-count shall be within 10% of the specified value, determined in accordance with 4.5.1. 3.6.2.3 Density The core density shall be within 10% of the nominal specified density, determined in accordance with 4.5.2. 4. QUALITY A
35、SSURANCE PROVISIONS 4.1 Responsibility for Inspection The manufacturer of the core shall supply all samples and shall be responsible for all required tests. Purchaser reserves the right to sample and to perform any confirmatory testing deemed necessary to ensure that the core conforms to the specifi
36、ed requirements. 4.2 Classification of Tests 4.2.1 Acceptance Tests Composition (3.1.1), density (3.2.1), cell count (3.2.1), foil thickness (3.2.1), compressive strength (3.4.1), shear strength (3.4.2), node bond strength (3.4.3), and flexibility (3.4.4) are acceptance tests and shall be performed
37、on each lot of foil or core as applicable. 4.2.2 Preproduction Tests All technical requirements are preproduction tests and shall be performed prior to or on the initial shipment of core by the manufacturer, when a change in ingredients and/or processing requires reapproval as in 4.4.2, and when pur
38、chaser deems confirmatory testing to be required. SAE AMS 4177D Page 7 of 11 4.3 Sampling and Testing Shall be in accordance with the following schedule: Composition (3.1.1): Each lot of foil Density (3.2.1): Each lot of core Cell Count (3.2.1): Each lot of core Foil Thickness (3.2.1): Each lot of c
39、ore Compressive Strength (3.4.1): Each lot of core Shear Strength (3.4.2): Each lot of core Node Bond Strength (3.4.3): Each lot of core Flexibility (3.4.4): Each lot of core Corrosion Resistance (3.4.5): Acceptable to purchaser 4.3.1 A lot of foil shall be all foil of one alloy in a single shipment
40、 from the foil producer. 4.3.2 A lot of core shall be all product fabricated at one time to form a block of expanded core. 4.4 Approval 4.4.1 Sample core shall be approved by purchaser before core for production use is supplied, unless such approval be waived by purchaser. Results of tests on produc
41、tion core shall be essentially equivalent to those on the approved sample. 4.4.2 Manufacturer shall use ingredients, manufacturing procedures, processes, and methods of inspection on production core which are essentially the same as those used on the approved sample. If necessary to make any change
42、in ingredients, in type of equipment for processing, or in manufacturing procedures, manufacturer shall submit for reapproval a statement of the proposed changes in ingredients and/or processing and, when requested, sample core. Production core made by the revised procedure shall not be shipped prio
43、r to receipt of reapproval. 4.5 Test Methods 4.5.1 Cell Count Shall be determined by actual count of cells per linear foot (meter) of transverse direction (See Figure 1). Make six determinations and report each value and the arithmetic mean. 4.5.2 Core Density Shall be determined by weight of a know
44、n volume. The test specimens shall be at least 12 x 12 inches (305 x 305 mm) x core thickness. The specimen dimensions shall be measured to the nearest 0.010 inch (0.25 mm) and weighed to an accuracy of 1.0%. Calculate density using Equation 1 for each of three determinations, reporting each value a
45、nd the arithmetic mean: Actual Density pounds per cubic footweight of specimen gramsVolume of specimen cubic inchesin inch pound unitskg mweight of specimen gVolume of specimen mmin SI units:.( , )(,/)(,=38133106(Eq. 1) SAE AMS 4177D Page 8 of 11 4.5.3 Node Bond Strength A 0.625T x 5L x 10W inch (15
46、.88T x 127L x 254W mm) core slice shall be tested in a suitable core tension fixture by mounting, without causing cell distortion, at opposite ends of the “W“ dimension (See Figure 1) with round pins. Pins shall be as large as cell size permits and engage all cells of a continuous row. Opposite pins
47、 shall be in mirror image alignment at a distance as near to 8 inches (203 mm) as this mounting method permits. The fixture shall be slotted to allow horizontal pin movement. A steady loading rate of 1.00 inch 0.05 (25.4 mm 1.3) per minute shall be maintained. 4.5.4 Flexibility Test A 10-inch (254-m
48、m) square specimen of the as-received thickness or a slice 0.625 inch 0.005 (15.88 mm 0.13) thick, whichever is thinner, shall be wrapped around a 4-inch (102-mm) diameter cylindrical mandrel at room temperature, first perpendicular and then parallel to the L direction of the core. Core under 0.625
49、inch (15.88 mm) in thickness shall use a mandrel in the same diametric ratio as for 0.625 inch (15.88 mm) thick core material. 4.5.5 Corrosion Resistance Representative specimens shall be 5 inches 1/16 (127 mm 1.6) long (longitudinal direction “L”, See Figure 1), 6 inches 1/16 (152 mm 1.6) wide (transverse direction “W”), and 0.625 inch 0.010 (15.88 mm 0.25) thick “T”. The core specimens shall be weig
